US Patent 10903527 Rolled 3D alkali metal batteries and production process

Provided is a rolled alkali metal battery wherein the alkali metal is selected from Li, Na, K, or a combination thereof; the battery comprising an anode having an anode active material, a cathode containing a cathode active material, and a separator-electrolyte layer, comprising a first electrolyte alone or a first electrolyte-porous separator assembly, in ionic contact with the anode and the cathode, wherein the cathode contains a wound cathode roll of at least a discrete layer of the cathode active material and an optional binder, at least a discrete layer of a conductive material, and at least a layer of a second electrolyte, identical or different in composition than the first electrolyte, wherein the wound cathode roll has a cathode roll length, a cathode roll width, and a cathode roll thickness and the cathode roll width is substantially perpendicular to the separator-electrolyte layer.